Combination reel and shipping container



July 4, 1967 L. MAYER COMBINATION REEL AND SHIPPING CONTAINER 2Sheets-Sheet 1 Filed Oct. 13, 1965 FIG.2

FIG.

INVENTOR. LO U! s MAYE R July 4, 1967 L. MAYER COMBINATION REEL ANDSHIPPING CONTAINER Filed Occ 13, 1965 FIGIS 2 Sheets-Sheet 2 FICAINVENTOR. LOU l S MAYER w. nfbehu'mk ATTORNEYS 3,329,259 COMBINATIONREEL AND SHIPPING CONTAINER Louis Mayer, Elmhurst, N.Y., assignor toOwens- Illinois, Inc., a corporation of Ohio Filed Oct. 13, 1965, Ser.No. 495,399 3 Claims. (Cl. 206--52) The present invention relates to anovel package construction.

More particularly, the present invention relates to a package whichembodies two functions; namely, a shipping package and, as well, a reeldispenser. Reel packages and dispensers for continuous lengths ofcoilable material are well-known in the art. One such package is disclosed in US. Patent 2,974,850. Additional packages of this general typeare disclosed in US. Patents 1,907,922, 2,330,117 and 2,092,626. Thesereel packages are desirably fabricated or paperboard, e.g., cardboard,chipboard or corrugated board. The latter is composed of two outer linerplies having adhesively sandwiched therebetween a convoluted corrugatingmedium. This material is commonly used in the packaging field by reasonof its relatively low cost, its relative stiffness and ease offabrication. It can also be rendered foldable by impressing scorelinesand perforations thereon. Corrugated board is also desirably used in thecontainer and carton fields because it is lightweight, thereby holdingshipping charges of the user to a minimum,

Presently employed designs of reel packages and shippers fabricated ofcorrugated board are not satisfactory since the ultimate consumer-usermust expend considerable effort in setting up the package from thedie-cut blanks furnished him. Furthermore, in the setting up,considerable accuracy is necessary in order to insure registrationand/or alignment of component parts of the corrugated construction.Additionally, in present designs, it is frequently necessary to employ aseparate cylindrical core in combination with the corrugated boardcomponents necessitating shipment, by the manufacturer of the corrugatedboard, of a separate order of the space-consuming cores or requiring theuser to order these components separately. Naturally, the latter alsonecessitates procedures for coordinating ordering of supplies ofdifferent components.

With the foregoing general introduction, it may be stated that it is aprincipal object of the present invention to provide a reelpackage/shipping container combination which is preassembled, is capableof being shipped essentially fiat and can be assembled and erected intoreel configuration with a minimum of effort and time expended.

It is also an object of the present invention to provide a combinationreel and shipping container package which is fabricated of relativelystiff sheet-like material of low cost and easy manipulation by the user.

It is likewise an object of the present invention to pro vide a low-costreel unit composed of inexpensive parts.

It is also an object of the present invention to provide a shippingcontainer which includes, as an integral part of the shipping containercomponent, a reel unit which is separable from the remainder of thecontainer proper.

It is still another object of the present invention to provide ashipping container; parts of which also comprise parts of a separablereel.

By a reel, of course, we mean and envision a generally annular core orspool member having circular flanges at each end, thereby defining anannular reservoir for a continuous length of coilable material. Examplesof the latter include, of course, wire, rope, twine, hose, insulation,pipe, tubing, and the like.

' United States Patent 3,329,259 Patented July 4, 1967 The foregoing, aswell as other objects of the present invention, will become apparent tothose skilled in the art from the following detailed description takenin conjunction with the annexed sheets of drawings on which there ispresented, for purposes of illustration only, a single embodiment of thepresent invention.

In the drawings:

FIG. 1 is a knocked-down plan view of a single sheet of corrugated boardwhich has been die-cut, scored and slotted in order to yield a blankrepresenting a preferred embodiment of the present invention.

FIG. 2 is a perspective view of the erected reel packageshippingcontainer fully assembled. (Contents have been deleted so as not toobscure the illustration of components.)

FIG. 3 is a plan view of a strip of corrugated board which can beincorporated into the reel package as an auxiliary support.

FIG. 4 is a side elevation view of two of the blanks shown in FIG. 1located in face-to-face, registering relationship and with certain partssecured together by stapling.

FIG. 5 is a sectional view taken on the line 5-5 in FIG. 2 showing theprincipal panel parts of the two blanks located in parallel spacedrelationship as assisted by the strip of corrugated board illustrated inFIG. 3.

FIG. 6 is a view similar to FIG. 5, but taken on the line 6-6 of FIG. 2and showing the incorporated strip of FIG. 3 and illustrating coiledmaterial in the package.

FIG. 7 is a perspective view of the reel portion of the package afterseverance from the remainder of the package as contemplated in apreferred] form of the invention.

The present invention envisions, according to one embodiment, a reelformed of relatively stilf sheet-like material; said reel including aspool or core composed of an annular array of flaps formed generallycentrally on a pair of spaced panel members; the flaps of one panelbeing connected to a corresponding flap on the other panel and togetherbridging the distance between the panels; said panels outwardly fromsaid flaps defining spaced retaining flanges for coilable materialwrapped about said spool.

In a related embodiment of the present invention, there is envisioned ashipping container comprising two principal parallel-spaced side wallshaving marginally attached closure flaps and flaps formed in the centralportion of the side walls by a plurality of radial cuts; said flapsbeing arranged in annular array; said flaps on respective side wallsbeing folded inwardly toward the flaps on the other side wall; saidflaps each including an inner end tab which is foldable into flushface-to-face contact with alike tab on an opposed flap extending fromthe other panel; said tabs being secured together; :said flaps inannular aggregate defining a core support about which a continuouslength of sheet material is wrapped for storage and shipping.

In a still further preferred embodiment, an elongate strip is Wrappedabout the core flaps to lend further support thereto and also serving tohold the side walls apart in material receiving relationship. In thisregard, the strip is cut to an appropriate width as to insure the properspacing of the side walls.

Referring now more specifically to the drawings, there is disclosed inFIG. 1 a plan view of a one-piece blank 11. The blank is formed ofcorrugated board composed of two liner sheets having adhesively securedtherebetween a convoluted corrugating medium. The blank 11 isessentially a square in which the principal central panel 12 is outlinedby marginal foldlines 13, 14, 15 and 16; which foldlines separate thecentral panel respectively from marginal flaps 18, 19, 20 and 21. Theend flap 20 has foldably attached minor end flaps 22 and 23 foldablysecured thereto and separated by foldlines 24 and 25. These end flapsare deleted in the other figures illustrating the invention in theinterest of clarity and simplicity of illustration. In a commercialembodiment, however, they are included and reference will be had lateron herein to their purpose and function.

The central panel 12 bears a circular perforation line 27; thetheoretical center of which corresponds with the center of the panel 12.The perforation serves as a separation line for the reel portion of theassembly in a manner to be described hereinafter. The panel 12 containsa central die-cut aperture 28 concentric with the perforation line 27. Aplurality of identical cuts 30 extend radially outward from the aperture28 an equal distance. In the embodiment shown, the cuts are eight innumber and they are disposed 45 apart. The extremities of the cuts 30are connected by an impressed scoreline 31, which defines an octagonconcentric with the die-cut aperture. The cuts and scores define anannular array of eight flaps F, which are foldable about the foldline 31separating same from the panel proper. Each of the flaps is providedwith a scoreline 33; each of which is parallel to the scoreline 31separating the associated flap from the blank proper, thereby definingeight foldable tabs T at the end extremities of the eight flaps.

Two identical blanks 11, die-cut and scored as shown in FIG. 1, areassembled or combined together in the manner shown in FIG. 4. Thus, thepanels are located in superimposed relationship with the edges inregistration. The lower panel bears the same reference numerals as inFIG. 4, but additionally the subscript a. Since the blanks are identicalin configuration, edge registration also provides registration of theflaps and tabs. The tabs T and Ta in overlying relationship are thensecured together by stitching or by stapling, as identified by referencelegend Z. In' this form, the secured-together two-blank assembly iswell-adapted to be shipped fiat to the con sumer who can, in a mannerabout to be described, convert this two-blank assembly into a reelmember adapted to receive an endless length of coilable material andthereafter converted by him into a shipping container of utility inconveying or transporting the product to his customer.

To convert the assembly of FIG. 4 into a reel, the panels 12 and 12a ofblanks 11 and 11a are simply moved apart into spaced relationship muchin the manner shown in FIG. 5. By reason of the scored foldlines 31 and33 andthe securement of the tabs, the flaps F move into normalrelationship with the principal panel 12, while the tabs remain in flushabutting relationship as shown in FIG. 2 and in FIG. 5. The flaps F inthis position are normally disposed to the panel proper. The tabs Twhich are secured together, on the other hand, are generally in parallelrelationship to the main blank surface and project radially inwardly.The normally disposed flaps F in the aggregate, therefore, define a coresupport about which an appropriate length of coilable material can bewound.

While the construction as just described can be successfully utilized,it is most desirable to employ a supporting member as shown in FIG. 3 inplan view. Support 35 is essentially a narrow rectangular strip whichmay be formed of any of the available relatively stiff sheet-likematerials, such as cardboard or corrugated board, chipboard, and thelike. As can be seen, it can be easily shipped flat by the producer ofthe package. The user can easily incorporate it into the structure, asshown in FIG. 5, and it is, in fact, shown in this figure in sectionWrapped about the array of flaps F. As shown, the ends of the strip 35are secured together by stitching or stapling. The dimensions thereof,of course, are selected so that the length corresponds generally to thecircumference of the core defined by the annuar array of flaps, whileits width is selected to conform to the distance separating the panels12 and 12a in their spaced condition, which is generally equal to thesum of the length of the fiaps F plus the sum of the thicknesses of thetabs T. The presence of the strip 35 provides insurance against anyaccidental collapse of the flaps about the scorelines 31 or 33. Themarginal flaps 18-21 and 18a-21a extend radially outwardly in order thatthe material to be wrapped around the core may be convenientlyintroduced into the peripheral cavity 50 defined between the majorportions of the panels 12 and 12a which define circular flanges, as itwere. It will be appreciated that the reel package, as illustrated inFIG. 5, may be conveniently mounted on a suitable jig and it, in turn,rotated for feeding the coilable material into the reel through thepassageway 50 defined by the open marginal flaps. Thereafter, themarginal closure fiaps 18 21 and 18a21a are conveniently overlapped andclosed by suitable stitching, stapling, adhesive tape, or the like. Thecoiled material M will thus be safely housed within a package which maybe shipped conveniently to the ultimate consumer.

A very desirable feature of the present invention is illustrated inFIGS. 2 and 7. FIG. 2 is like FIG. 6; that is, illustrating a completedcarton in perspective; however, the coiled material is deleted in FIG. 2in the interest of clarity. FIG. 2 does, however, show a scoreseparation line 27 in the upper panel 12, while another separation line27a is indicated in clotted outline in the lower panel 12a. Thesubscript a is again utilized to identify components of the lower blank11a (see FIG. 4). These separation lines are perforations imparted tothe blank 11 as it is produced and as described in connection with thedescription in FIG. 1. The ultimate user of the material within thepackage finds this reel-container assembly very convenient since heneeds simply to break tthe package apart on the circular separationlines 27 and 27a and thence lift out the reel portion containing thecoiled material thereon, as shown in FIG. 7. The remainder of the cartonshown on the left in FIG. 7 can then be discarded. The reel identifiedby the reference letter R in FIG. 7 can then, if desired, be mounted onany rotatable cylindrical form to permit the material to be withdrawn.Of course, it can be laid fiat on any of the side panels 12 or 12a andthe material removed conveniently.

Referring once again to FIG. 1, it may be noted that in a commercialembodiment cor-ner flaps 22 and 23 are usually employed. In such case,the superimposition of two blanks as in FIG. 4 is done in such fashionthat corner flaps 22 and 23 are located at each corner, whereuponultimate assembly and closure will find a corner end flap, e.g., 22,available for insertion between its foldably associated flap, e.g., flap20, and the next adjacent fiap, e.g., flap 21, separated by the slot.The corner flap serves to provide reinforcement in the corner areas in amanner well-known in the art and, additionally, prevents entry offoreign materials through the corners of the assembled package,precluding the necessity of taping the corners to prevent entry offoreign material.

The number of flaps is usually fixed at eight since this closelyapproximates a circle. A greater number, of course, may be used since itwill be appreciated that the greater number will even more closelyapproximate a circle. This has a disadvantage, however, of increasingthe manufacturing costs since more staples and additional stapling orstitching operations must be employed. A lesser number of flaps thaneight may be employed but, as one reduces the number of flaps, one, ofcourse, departs from a circular core. For example, four flaps result inthe formation of a core which is essentially square. As a consequence,if a strip such as 35 is employed, it will be subject to collapse sinceit will be supported at only four points, as routine experimentationwill illustrate.

Modifications may be resorted to without departing from the spirit andscope of the invention disclosed herei-nabove and claimed hereinafter.

I claim:

1. A generally square planar sheet, an aperture in said sheet generallycentrally of said sheet, a plurality of flap members surrounding saidaperture, said flap members being separated by radi-al cuts through saidsheet-like m-aterial, said flap members including scorelines joining theouter extent of said cuts and being foldable about said scorelines, atab member formed on each flap at the inner segment thereof, said tabsbeing separated from the associated flap by a foldline generallyconcentric with respect to the foldline connecting said cuts, said sheetincluding marginally attached closure flaps at the edges, and said sheetincluding a closed perforated separation line surrounding said flapmembers and spaced therefrom to thereby define, in combination with alike blank, in which the registering tab members thereof are securedtogether and when the flaps and tabs are in normal relationship, anannular reservoir for a continuous length of coilable material.

2. A reel carton comprising a pair of parallel-spaced panels formed ofrelatively stiif sheet-like material, marginal flaps foldably attachedto said panels serving to form peripheral overlapping closure means,said panels each having a central aperture, a plurality of foldable flapmembers formed about said aperture by cuts extending radially outwardfrom said aperture, a foldable end tab formed on the inner extremity ofeach flap member, said flaps being folded inwardly into normalrelationship with their associated panel, said tabs being foldedinwardly toward each other into flush face-to-face contact with the tabsof the opposite panel, means for securing said tabs together and a stripof said material wrapped peripherally about said flaps, said strip andabutting flaps defining a spool for continuous material coiled thereon,said strip having a width generally equal to the spacing of said panels,said panels each including a circular line of perforations spacedconcentrically outwardly from s-aid flaps.

3. A preassembled, knocked-down combination reel and shipping container,said combination being formed of stiff paper material and including apair of substantially identical flat, generally rectangular blanks, eachhaving a central circular aperture, a plurality of radial slitsextending outwardly from said aperture to define an annular array offlaps, scorelines connecting the outer ends of said slits to providefoldability to said flaps, scorelines on each of said flaps parallelwith the first-mentioned scores to define foldable tab portions on theinner extremities of said flaps, said pair of blanks being infaceto-face registering relations-hip, opposed tabs of each of said pairof blanks being secured together, said blanks each including a circularline of perforations spaced generally concentrically outwardly of saidflaps and said blanks including relatively foldable closure fiapsmarginally connected thereto, said blanks being movable into spaced,parallel relationship when folded on said scorelines in each flapwhereby said flaps define a spool and there-about an annular reservoirfor coilable product.

References Cited UNITED STATES PATENTS 2,527,401 10/1950 Daoust 206-522,591,576 4/1952 McCormick 206-52 2,794,546 6/1957 Miller 206-522,832,466 4/1958 Sheard 229-41 3,222,011 12/1965 Webb 242-118.8

THERON E. CONDON, Primary Examiner. WILLIAM T. DIXSON, IR., Examiner.

3. A PREASSEMBLED, KNOCKED-DOWN COMBINATION REEL AND SHIPPING CONTAINER,SAID COMBINATION BEING FORMED OF STIFF PAPER MATERIAL AND INCLUDING APAIR OF SUBSTANTIALLY IDENTICAL FLAT, GENERALLY RECTANGULAR BLANKS, EACHHAVING A CENTRAL CIRCULAR APERTURE, A PLURALITY OF RADIAL SLITSEXTENDING OUTWARDLY FROM SAID APERTURE TO DEFINE AN ANNULAR ARRAY OFFLAPS, SCORELINES CONNECTING THE OUTER ENDS OF SAID SLITS TO PROVIDEFOLDABILITY TO SAID FLAPS, SCORELINES ON EACH OF SAID FLAPS PARALLELWITH THE FIRST-MENTIONED SCORES TO DEFINE FOLDABLE TAB PORTIONS ON THEINNER EXTREMITIES OF SAID FLAPS, SAID PAIR OF BLANKS BEING INFACETO-FACE REGISTERING RELATIONSHIP, OPPOSED TABS OF EACH OF SAID PAIROF BLANKS BEING SECURED TOGETHER, SAID BLANKS EACH INCLUDING A CIRCULARLINE OF PERFORATIONS SPACED GENERALLY CONCENTRICALLY OUTWARDLY OF SAIDFLAPS AND SAID BLANKS INCLUDING RELATIVELY FOLDABLE CLOSURE FLAPSMARGINALLY CONNECTED THERETO, SAID BLANKS BEING MOVABLE INTO SPACED,PARALLEL RELATIONSHIP WHEN FOLDED ON SAID SCORELINES IN EACH FLAPWHEREBY SAID FLAPS DEFINE A SPOOL AND THEREABOUT AN ANNULAR RESERVOIRFOR COILABLE PRODUCT.